Skyjack SJ30AJE Service Manual Download

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SERVICE

MANUAL

ARTICULATING BOOM

196274AF

November 2018
ANSI/CSA, CE, AS, KC

SJ30AJE, SJ30ARJE

Summary of Contents for SJ30AJE

Page 1: ...SERVICE MANUAL ARTICULATING BOOM 196274AF November 2018 ANSI CSA CE AS KC SJ30AJE SJ30ARJE ...

Page 2: ...rial Numbers SJ30AJE SJ30ARJE 90 000 001 to 90 999 999 Please refer to the website www skyjack com for contact information other Serial Numbers the most recent Technical Manuals and USB software Original instructions in English ...

Page 3: ...ult in death or serious injury WARNING WARNING indicates a potentially hazardous situation which if not avoided could result in death or serious injury CAUTION CAUTION indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury It may also be used to alert against unsafe practices IMPORTANT IMPORTANT indicates a procedure essential for safe operation and...

Page 4: ...4 SJ30AJE SJ30ARJE 196274AF Notes ...

Page 5: ...e and Repair 13 1 2 6 Hydraulic Maintenance Hints 13 1 2 7 Railing Maintenance and Repair 14 1 3 Scheduled Maintenance 15 1 3 1 Service Bulletins 15 1 3 2 Maintenance and Inspection 15 1 3 3 Maintenance Instructions 15 1 4 Owner s Annual Inspection Record 16 1 5 Pre Delivery Maintenance Inspection Checklist 17 1 6 Scheduled Maintenance Inspections 18 1 6 1 Labels 18 1 6 2 Electrical 18 1 6 3 Limit...

Page 6: ...ose Port Identification 55 3 8 Main Manifold Electrical Component Identification 56 3 9 Main Manifold Component Identification 57 3 10 Main Manifold Harness ANSI CSA CE AS 58 3 11 Main Manifold Harness KC 59 3 12 Control Cables Harnesses 60 3 13 Platform Limit Switch Harness KC 61 3 14 Emergency Pump Base Controls Wiring 62 3 15 Direction Sensing Limit Switch Base Control Wiring 63 3 16 High Speed...

Page 7: ...rm Rotate Right from Base Control Console 94 4 2 15 No Jib Up from Base Control Console 95 4 2 16 No Jib Down from Base Control Console 96 4 2 17 No Jib Rotate Right from Base Control Console 97 4 2 18 No Jib Rotate Left from Base Control Console 98 4 2 19 No Manual Platform Level Up from Base Control Console 99 4 2 20 No Manual Platform Level Down from Base Control Console 100 4 2 21 All Controls...

Page 8: ...No Turret Rotate Left 121 4 3 7 No Turret Rotate Right 121 4 3 8 No Boom Extend 122 4 3 9 No Boom Retract 122 4 3 10 No Jib Up 122 4 3 11 No Jib Down 123 4 3 12 No Platform Rotation Right 123 4 3 13 No Platform Rotation Left 123 4 3 14 No Jib Rotation Right 124 4 3 15 No Jib Rotation Left 124 4 3 16 Platform will not Level Down Manually 125 4 3 17 Platform will not Level Up Manually 125 4 3 18 No ...

Page 9: ...Rotary Actuator Bolt Torque Sequence 149 5 5 Turret 150 5 5 1 Hydraulic Oil Replacement 150 5 5 2 Hydraulic Filter Replacement 150 5 5 3 Hydraulic System Main Relief Valve Adjustment RV1 151 5 5 4 Main Pump Relief Valve Adjustment RV5 151 5 5 5 Emergency Pump Relief Valve Adjustment RV6 152 5 5 6 Turret Rotate Relief Valve Adjustment RV3 152 5 5 7 Riser Down Relief Valve Adjustment RV7 153 5 5 8 B...

Page 10: ...10 SJ30AJE SJ30ARJE 196274AF 5 7 1 Lubrication 188 ...

Page 11: ...ded weather resistant storage compartment on the MEWP at all times Service Maintenance The purpose of this is to provide the customer with the servicing and maintenance procedures essential for the promotion of proper machine operation for its intended purpose All information in this manual should be read and understood before any attempt is made to service the machine The updated copy of the manu...

Page 12: ...tions and installation WARNING Any unit that is damaged or not operating properly must be immediately tagged and removed from service until proper repairs are completed 1 2 4 Maintenance and Service Safety Tips Maintenance and repair should only be performed by personnel who are trained and qualified to service this MEWP All maintenance and service procedures should be performed in a well lighted ...

Page 13: ...eservoir and fill the reservoir only through the filter opening The use of cloth to strain the oil should be avoided to prevent lint from getting into the system 6 When removing any hydraulic component be sure to cap and tag all hydraulic lines involved Also plug the ports of the removed components 7 All hydraulic components must be disassembled in spotlessly clean surroundings During disassembly ...

Page 14: ...limited to the items listed below bent deformed guardrail sections cracks or broken welds in railing sections damaged pin connections missing pins or broken pin lanyards missing railing hardware loose or missing parts additional holes in guardrail sections other than those approved by Skyjack Additionally the guardrails must be properly positioned and secured and the entry gate must be in good wor...

Page 15: ...n the following configuration MEWP parked on a flat and level surface Disconnect the batteries by disconnecting the main power connectors Repair any damaged or malfunction components before operating MEWP Keep records on all inspections 1 3 3 Maintenance Instructions This manual consists of four schedules to be done for maintenance on a MEWP The inspection schedule frequency is shown below Issue o...

Page 16: ...n Record Table Description Label Pictorial 1 Inspection Date Description Label Pictorial 2 Inspector Signature 1 2 Figure 01 This decal is located on the controls side cowling It must be completed after an annual inspection has been completed Do not use the MEWP if an inspection has not been recorded in the last 13 months ...

Page 17: ...s Tight wire connections and no damage or missing parts B SGE Secure No damage or missing parts Tie Rod No damage wear or missing parts Pothole Protection No cracks damage or deformation Hydraulic Filter Secure and no damage missing parts or leaks B C Manuals Required Documents In storage box in good condition and legible B B Battery Trays Latches and lids are secure No missing parts Torque Hubs S...

Page 18: ...e in place and are legible 1 6 2 Electrical Maintaining the electrical components is essential to the good performance and service life of the MEWP Inspect the following areas for chafed corroded and loose wires boom to platform cable harness engine compartment electrical panel engine wiring harness rotary manifold wiring 1 6 3 Limit Switches B Ensure limit switches 1 are properly secured with no ...

Page 19: ...e and in proper working order 1 Base Control Console B Ensure all switches are returned to their neutral positions Ensure there are no loose or missing parts and there is no visible damage 2 Main Manifold B Ensure all fittings and hoses are properly tightened and there is no evidence of hydraulic leakage Ensure there are no loose wires or missing fasteners 1 2 ...

Page 20: ...ydraulic oil tank Ensure the hydraulic oil level is within the minimum and maximum range found on the hydraulic oil level indicator label Add oil as needed Refer to 2 9 Hydraulic Specifications for recommended oil type 4 Hydraulic Filter B Ensure the housing is secure and shows no visible damage or leakage 5 Emergency Power Unit B Ensure there are no loose or missing parts and there is no visible ...

Page 21: ...ge B Ensure there are no loose or missing parts tie rod end studs are locked and there is no visible damage 6 Wheel Tire Assembly B C The MEWP is equipped with solid rubber tires Tire and or wheel failure could result in a MEWP tip over Component damage may also result if problems are not discovered and repaired in a timely fashion Check all tire treads and sidewalls for cuts cracks punctures and ...

Page 22: ...sparks away Do not smoke near the batteries WARNING Battery acid is extremely corrosive Wear proper eye and facial protection as well as appropriate protective clothing If contact occurs immediately flush with cold water and seek medical attention Check the battery cases for damage B Frequent Inspection Clean the battery terminals and cable ends thoroughly with a terminal cleaning tool or wire bru...

Page 23: ... the footswitch 4 is in good working order and has not been modified disabled or blocked Ensure the AC outlet 5 has no visible damage and is free from dirt or obstruction 6 Platform Control Console B Ensure all switches controllers are returned to neutral Ensure there are no loose or missing parts and there is no visible damage 7 Manuals Ensure a copy of the operating manual and other important do...

Page 24: ...d and there is no evidence of hydraulic leakage 4 Cylinders B Ensure all cylinders are properly secured and there is no evidence of leakage Ensure all fittings and hoses are properly tightened and there is no evidence of damage 5 Wear Pads B Ensure all bolts are tight there is no visible damage to the wear pads and no parts are missing 6 E Chain B Ensure there are no loose or missing parts and the...

Page 25: ...ires or missing fasteners 2 Flashing Amber Light Ensure the lamp is properly secured with no signs of visible damage 3 Inverter Ensure the inverter is properly secured with no signs of visible damage 4 Pipe Rack Ensure the pipe rack assemblies are properly secured with no signs of visible damage 5 Control Box Cover Ensure the control box cover is properly secured with no signs of visible damage 6 ...

Page 26: ... qualified competent repair personnel After repairs are completed the operator must perform a pre operation inspection and a series of function tests again before putting the MEWP into service Prior to performing function tests be sure to read and understand the Start Operation section of the operating manual For function test that are to be performed please refer to the operating manual that corr...

Page 27: ...IC SWIVEL 100R17 H02 FEMALE 37 JIC SWIVEL FEMALE 37 JIC SWIVEL 100R13 H03 FEMALE 37 JIC SWIVEL 45 FEMALE 37 JIC SWIVEL 100R17 H04 FEMALE 37 JIC SWIVEL 45 FEMALE 37 JIC SWIVEL 100R13 H05 FEMALE 37 JIC SWIVEL LONG 90 FEMALE 37 JIC SWIVEL 100R17 H06 FEMALE 37 JIC SWIVEL SHORT 90 FEMALE 37 JIC SWIVEL 100R17 H07 LONG 90 FEMALE 37 JIC SWIVEL LONG 90 FEMALE 37 JIC SWIVEL 100R17 H08 FEMALE 37 JIC SWIVEL F...

Page 28: ... H38 SHORT 90 FEMALE 37 JIC SWIVEL FEMALE 37 JIC SWIVEL 100R4 H39 LONG 90 FEMALE 37 JIC SWIVEL FEMALE 37 JIC SWIVEL 100R4 H40 SHORT 90 FEMALE 37 JIC SWIVEL FEMALE 37 JIC SWIVEL 100R16 H43 FEMALE 37 JIC SWIVEL FEMALE 37 JIC SWIVEL 100R16 H51 FEMALE 37 JIC SWIVEL FEMALE 37 JIC SWIVEL 100R17 H52 SHORT 45 FEMALE 37 JIC SWIVEL FEMALE 37 JIC SWIVEL 100R17 H53 MEDIUM 45 FEMALE 37 JIC SWIVEL FEMALE 37 JIC...

Page 29: ... 3 8 16 x 3 25 Grade 5 30 41 Cylinders Main Lift PISTON 578 784 PISTON SET SCREW 11 15 GLAND 491 666 Extension ROD NUT 289 392 GLAND 318 431 Master PISTON 542 735 PISTON SET SCREW 11 15 GLAND 462 626 Slave ROD NUT 289 392 GLAND 462 626 Riser PISTON 434 588 PISTON SET SCREW 6 8 GLAND 376 510 Jib PISTON 324 439 PISTON SET SCREW 6 8 GLAND 318 431 Steer PISTON 361 489 PISTON SET SCREW 6 8 GLAND 318 41...

Page 30: ...bed includes lubricants such as lubrizing oil grease or uncured Loctite 1374AA Size Torque Type SAE2 SAE 5 SAE 8 Dry Lubed Dry Lubed Dry Lubed 9 16 12 ft lb 70 55 110 80 150 110 Nm 95 75 149 108 203 149 9 16 18 ft lb 80 60 120 90 170 130 Nm 108 81 163 122 230 176 5 8 11 ft lb 100 75 150 110 220 170 Nm 136 102 203 149 298 230 5 8 18 ft lb 110 85 180 130 240 180 Nm 149 115 244 176 325 244 3 4 10 ft ...

Page 31: ...32 Nm 88 66 126 94 4 9 3 6 M14 x 2 00 ft lb 104 78 148 111 60 45 Nm 141 106 201 150 6 8 5 1 M16 x 2 00 ft lb 161 121 230 172 68 51 Nm 218 164 312 233 7 7 5 8 M18 x 2 50 ft lb 222 167 318 238 12 9 Nm 301 226 431 323 16 12 M20 x 2 50 ft lb 314 235 449 337 14 10 Nm 426 319 609 457 19 14 M22 x 2 50 ft lb 428 321 613 460 25 18 Nm 580 435 831 624 34 24 M24 x 3 00 ft lb 543 407 776 582 25 20 Nm 736 552 1...

Page 32: ...222 294 32 1276AA Hose End Torque Chart for JIC Size Steel Brass Dash Frac ft lb Nm ft lb Nm Min Max Min Max Min Max Min Max 4 1 4 10 11 13 15 5 6 6 75 9 6 3 8 17 19 23 26 12 15 17 20 8 1 2 34 38 47 52 20 24 27 66 33 10 5 8 50 56 69 76 34 40 46 33 55 12 3 4 70 78 96 106 53 60 72 33 82 16 1 94 104 127 141 74 82 100 5 111 20 1 1 4 124 138 169 188 75 83 101 5 113 24 1 1 2 156 173 212 235 79 87 107 11...

Page 33: ... 2 Person s 1 Person s Maximum Wind 0 mph 0 m s 28 mph 12 5 m s Maximum Side Force 90 lbf 400 N 45 lbf 200 N 1172AA_ANSI SJ30AJE SJ30ARJE Total Capacity 500 lb 227 kg WARNING Do not use tires other than those specified for this machine Do not mix different types of tires Tires other than those specified can adversely affect stability Failure to operate with matched approved tires in good condition...

Page 34: ...ial platform tire tread presses on the area in direct contact with the floor The floor covering tile carpet etc must be able to withstand more than the indicated values above OUP Overall Uniform Pressure is a measure of the average load the aerial platform imparts on the whole surface projected directly underneath it The structure of the operating surface beams etc must be able to withstand more t...

Page 35: ...CC Pressure 3000 psi 207 bar Jib Rotary Actuator Displacement 14 3 CI 234 3 CC Pressure 3000 psi 207 bar Cylinders Extension Cylinder Bore 1 96 in 5 0 cm Rod Diameter 1 38 in 3 5 cm Stroke 46 in 116 8 cm Maximum Operating Pressure 1250 psi 86 bar Test Pressure 3000 psi 207 bar Main Boom Lift Cylinder Bore 3 15 in 8 0 cm Rod Diameter 1 77 in 4 5 cm Stroke 2400 psi 56 6 cm Test Pressure 3000 psi 207...

Page 36: ...77 in 4 5 cm Rod Diameter 1 38 in 3 5 cm Stroke 22 2 in 56 4 cm Maximum Operating Pressure 2000 psi 138 bar Test Pressure 3000 psi 207 bar Steer Cylinder Bore 2 in 5 0 cm Rod Diameter 1 in 2 5 cm Stroke 7 44 in 18 9 cm Maximum Operating Pressure 2000 psi 138 bar Test Pressure 3000 psi 207 bar Hydraulic Oil Standard Shell Tellus T46 Petro Canada Hydrex MV46 15 F to 100 F 26 C to 38 C Biodegradable ...

Page 37: ...t stowed 6 6 1 98 m 6 6 1 98 m Length stowed 18 2 5 64 m 18 1 5 51 m Height transport 8 3 2 51 m 8 2 2 49 m Length transport 13 1 3 99 m 12 5 3 78 m Width 3 11 1 19 m 3 11 1 19 m Wheelbase 5 5 1 80 m 5 5 1 80 m Ground Clearance Chassis 4 0 10 m 4 0 10 m Turning Radius Inside Left Right 5 1 2 5 5 1 54 x 1 65 m 5 1 2 5 5 1 54 x 1 65 m Turning Radius Outside Left Right 10 6 10 11 3 20 x 3 33 m 10 6 1...

Page 38: ... s Jib Swing Time 14 16 s 14 16 s 14 16 s 14 16 s Jib Up Time 18 20 s 18 20 s 18 20 s 18 20 s Jib Down Time 12 16 s 12 16 s 12 16 s 12 16 s Steer Left Right Time 2 4 s 2 4 s 2 4 s 2 4 s Tire Data Tire Size 22 x 7 5 59 x 1 78 m 22 x 7 5 59 x 1 78 m Diameter Outside 22 5 59 m 22 5 59 m Width 7 1 78 m 7 1 78 m Electrical Data Battery Voltage 48V DC 48V DC 48V DC 48V DC Battery Type Lead Acid Lead Aci...

Page 39: ... m 1 98 m Length stowed 5 51 m 5 51 m 5 51m Height transport 2 50 m 2 50 m 2 50 m Length transport 3 80 m 3 80 m 3 8 m Width 1 19 m 1 19 m 1 19 m Wheelbase 1 65 m 1 65 m 1 65 m Ground Clearance Chassis 0 01 m 0 01 m 0 01 m Turning Radius Inside Left Right 1 53 1 65 m 1 53 1 65 m 1 53 1 65 m Turning Radius Outside Left Right 3 21 3 32 m 3 21 3 32 m 3 21 3 32 m Turning Angle 76 76 76 Turret Rotation...

Page 40: ...6 s 22 26 s 22 26 s Jib Swing Time 14 16 s 14 16 s 14 16 s Jib Up Time 18 20 s 18 20 s 18 20 s Jib Down Time 12 16 s 12 16 s 12 16 s Steer Left Right Time 2 4 s 2 4 s 2 4 s Tire Data Tire Size 5 59 x 1 78 m 5 59 x 1 78 m 5 59 x 1 78 m Diameter Outside 5 59 m 5 59 m 5 59 m Width 1 78 m 1 78 m 1 78 m Electrical Data Battery Voltage 48V DC 48V DC 48V DC Battery Type Lead Acid Lead Acid Lead Acid Weig...

Page 41: ...JE SJ30ARJE 196274AF Reach Diagram SJ30AJE Section 2 Maintenance Tables and Diagrams 5 ft 0 ft 5 ft 10 ft 15 ft 20 ft 25 ft 40 ft 35 ft 30 ft 25 ft 20 ft 15 ft 10 ft 5 ft 0 ft 2 12 Reach Diagram SJ30AJE Diagram ...

Page 42: ...ion Diagram SJ30AJE 29 8 9 04 m 75 5 65 5 77 5 4 1 1 24 m 8 3 2 51 m 4 3 1 30 m 1 3 0 38 m 13 1 4 00 m 6 6 1 98 m 4 0 10 m 13 1 3 99 m 5 5 1 65 m 18 2 5 64 m 5 5 1 65 m 16 9 5 11 m 20 7 6 27 m 2 6 0 76 m 3 10 1 17 m 36 3 11 1 m 2 11 0 90 m 2 13 Dimesion Diagram SJ30AJE Diagram ...

Page 43: ... 196274AF Reach Diagram SJ30ARJE Section 2 Maintenance Tables and Diagrams 5 ft 10 ft 15 ft 20 ft 25 ft 30 ft 35 ft 0 10 ft 5 ft 0 5 ft 10 ft 180 5 ft 0 ft 5 ft 10 ft 15 ft 20 ft 25 ft 2 14 Reach Diagram SJ30ARJE Diagram ...

Page 44: ...mension Diagram SJ30ARJE 13 1 4 m 6 6 1 98 m 77 5 75 5 66 5 4 1 1 24 m 2 11 0 90 m 8 2 2 5 m 4 3 1 30 m 1 0 30 m 4 0 10 m 5 5 1 65 m 12 5 3 78 m 18 1 5 51 m 20 7 6 26 m 16 9 5 10 m 3 11 1 19 m 2 6 0 76 m 3 10 1 17 m 36 1 11 m 29 6 9 m 2 15 Dimension Diagram SJ30ARJE Diagram ...

Page 45: ...45 SJ30AJE SJ30ARJE 196274AF Section 3 System Component Identification and Schematics ...

Page 46: ...S CROSSING NO CONNECTION CIRCUITS CONNECTED BATTERY FUSE GROUND CIRCUIT BREAKER VOLT METER CAPACITOR POTENTIOMETER SINGLE POLE DOUBLE THROW RELAY TRIPLE POLE DOUBLE THROW RELAY RELAY RELAY DOUBLE POLE DOUBLE THROW SINGLE POLE SINGLE THROW CAM OPERATED LIMIT SWITCH LIMIT SWITCH ROTARY SWITCH PUSH BUTTON TOGGLE SWITCH FOOT SWITCH KEY SWITCH TEMPERATURE SWITCH LIMIT SWITCH N O LIMIT SWITCH N O HELD C...

Page 47: ...RAKE CYLINDER CYLINDER CHECK VALVE COUNTER BALANCE VALVE ROTARY ACTUATOR OIL COOLER VALVE COIL BI DIRECTIONAL HYDRAULIC MOTOR TWO POSITION TWO WAY NORMALLY CLOSED VALVE TWO POSITION THREE WAY VALVE THREE POSITION FOUR WAY CLOSED CENTER OPEN PORT TWO POSITION THREE WAY VALVE TWO POSITION TWO WAY NORMALLY OPEN VALVE THREE POSITION FOUR WAY CLOSED CENTER CLOSED PORT PRESSURE TRANSDUCER MAIN LINES Sol...

Page 48: ...4 GRN ORG 08 PUR WHT 31 RED WHT 54 PUR RED 77 BRN GREY 105 GRN BRN 09 YEL 32 GRN BLK 55 YEL PUR 78 RED BLU 106 GRN PINK 10 BLU WHT 33 GRN WHT 56 YEL BLK 79 BRN PUR 107 BLK BLU 11 WHT ORG 34 ORG BLK 57 BRN GRN 80 GREY WHT 108 YEL BRN 12 RED YEL BLK 35 ORG WHT 58 WHT PUR 81 GREY BLK 109 GRN YEL 13 ORG 36 RED PUR 59 YEL BLU 82 BRN WHT 110A BLU 14 BLK 37 WHT RED BLK 60 WHT BLU 83 BLU GREY 110B BRN 15 ...

Page 49: ...149372 1 VALVE Counterbalance jib elevation CB8 149372 1 VALVE Counterbalance jib elevation CB9 209153 1 VALVE Counterbalance platform rotary actuator CB10 209153 1 VALVE Counterbalance platform rotary actuator CB11 141453 1 VALVE Counterbalance jib rotary actuator CB12 141453 1 VALVE Counterbalance jib rotary actuator CV1 199471 1 VALVE Check main manifold CV2 208883 1 VALVE Check main manifold C...

Page 50: ... main manifold RV5 209058 1 VALVE Relief main pump RV6 209058 1 VALVE Relief auxiliary pump RV7 209110 1 VALVE Relief riser cylinder V1 208872 1 VALVE Control steer cylinder V2 166036 1 VALVE Control master cylinder V3 166041 1 VALVE Control main boom lift V4 208875 1 VALVE Control turret rotary actuator V5 208874 1 VALVE Control riser cylinder V6 166050 1 VALVE Control flow enable V7 166036 1 VAL...

Page 51: ...12V 40 amp base controls 60CR 127131 1 RELAY 12V 40 amp base controls 162BCR 127131 1 RELAY 12V 40 amp base controls CE 162CR 127131 1 RELAY 12V 40 amp base controls 204CR 127131 1 RELAY 12V 40 amp platform controls 208CR 127131 1 RELAY 12V 40 amp base controls 208CR1 127131 1 RELAY 12V 40 amp platform controls 259CR 127131 1 RELAY 12V 40 amp base controls 2H 20A 166127 1 COIL 12 Volt flow enable ...

Page 52: ...ib rotate right 5H 32 208881 1 COIL 12 Volt turret rotate left 5H 33 208881 1 COIL 12 Volt turret rotate right A1 138224 1 JOYSTICK Drive steer A2 138225 1 JOYSTICK Boom turret A3 138226 1 SWITCH Speed control BP1 144387 1 ALARM Tilt BP2 103057 1 ALARM All motion BP3 144387 1 ALARM Overload BP4 166110 1 BEEPER SGE CAP1 164511 1 CAPACITOR 10 000 µF CB1 137919 1 CIRCUIT BREAKER 25 amp CB2 137919 1 C...

Page 53: ... CE S4 144647 1 SWITCH Emergency stop platform S5 144648 1 SWITCH Horn platform S6 700187 1 FOOTSWITCH platform S7 102853 1 SWITCH Riser up down platform S8 102853 1 SWITCH Telescope in out platform S9 102853 1 SWITCH Jib up down platform S10 102853 1 SWITCH Jib rotate platform SJ30ARJE S11 102853 1 SWITCH Platform rotate platform S12 102853 1 SWITCH Platform leveling platform S13 102853 1 SWITCH ...

Page 54: ...Left PA To Platform Rotator Right JA To Jib Cylinder Extend T To Main Manifold T2 P To Main Manifold POUT JR To Jib Rotator Right 4H 35 Jib Up 4H 34 Jib Down 4H 37 Platform Right 4H 36 Platform Left 4H 43 Jib Right 4H 42 Jib Left JB To Jib Cylinder Retract PB To Platform Rotator Left JA To Jib Cylinder Extend T To Main Manifold T2 P To Main Manifold POUT JR To Jib Rotator Right 4H 35 Jib Up 4H 34 ...

Page 55: ...der Extend SWB To Swing Drive Motor LB To Boom Lift Cylinder Retract LA To Boom Lift Cylinder Extend PLB To Master Cylinder PLA To Master Cylinder STL To Steer Cylinder STR To Steer Cylinder GP To Test Port T1 To Hydraulic Tank POUT To Jib Manifold T2 To Jib Manifold EB EA POUT T2 RA RB SWB SWA STR STL PLA PIN T1 PLB LB LA PIN To Pumps 3 7 Main Manifold Hose Port Identification M192161AC 1 ...

Page 56: ...y Boom Extend 4H 38 Fly Boom Retract 2H 20A Flow Enable 5H 33 Turret Right 5H 32 Turret Left 4H 14 Boom Up 4H 13 Boom Down 4H 40 Platform Level Down 4H 224 Steer Left 4H 223 Steer Right 4H 41 Platform Level Up 2H 31 Riser Up 2H 30 Riser Down located on riser cylinder 3 8 Main Manifold Electrical Component Identification ...

Page 57: ...Main Manifold Component Identification M192161AC 3 CV2 Check Valve CV3 Check Valve RV2 Relief Valve CV1 Check Valve RV3 Relief Valve RV4 Relief Valve RV1 Relief Valve OR1 Oriﬁce GP Test Port CV2 CV3 ORF1 R V 1 G P R V 4 C V 1 R V 2 R V 3 DPOCV1 Check Valve DC1 ...

Page 58: ...UE PURPLE PIN 2 02 WHITE STEER RIGHT PIN 1 7A RED PIN 2 223 BLACK WHITE STEER LEFT PIN 1 7A RED PIN 2 224 BLUE BLACK BOOM UP PIN 1 14 BLACK PIN 2 02 WHITE FLOW ENABLE PIN 1 20B WHITE RED PIN 2 02 WHITE RISER UP PIN 1 31 RED WHITE PIN 2 02 WHITE BOOM DOWN PIN 1 13 ORANGE PIN 2 02 WHITE WIRE LIST WIRE 1 13 ORANGE WIRE 2 14 BLACK WIRE 3 20B WHITE RED WIRE 4 223 BLACK WHITE WIRE 5 224 BLUE BLACK WIRE ...

Page 59: ...E PIN 2 02 WHITE STEER RIGHT PIN 1 7A RED PIN 2 223 BLACK WHITE STEER LEFT PIN 1 7A RED PIN 2 224 BLUE BLACK BOOM UP PIN 1 14A BLACK PIN 2 02 WHITE FLOW ENABLE PIN 1 20B WHITE RED PIN 2 02 WHITE RISER UP PIN 1 31A RED WHITE PIN 2 02 WHITE BOOM DOWN PIN 1 13 ORANGE PIN 2 02 WHITE WIRE LIST WIRE 1 13 ORANGE WIRE 2 14A BLACK WIRE 3 20B WHITE RED WIRE 4 223 BLACK WHITE WIRE 5 224 BLUE BLACK WIRE 6 31A...

Page 60: ...ION 15 BLUE WHITE POSITION 16 BLACK RED WIRE POSITIONS POSITION 1 BLACK POSITION 2 WHITE POSITION 3 RED POSITION 4 GREEN POSITION 5 ORANGE POSITION 6 BLUE POSITION 7 WHITE BLACK POSITION 8 RED BLACK POSITION 9 GREEN BLACK POSITION 10 ORANGE BLACK POSITION 11 BLUE BLACK POSITION 12 BLACK WHITE POSITION 13 RED WHITE POSITION 14 GREEN WHITE POSITION 15 BLUE WHITE POSITION 16 BLACK RED POSITION 17 WHI...

Page 61: ...2A 3 WHITE 51A 4 BLACK 51 ID COLOUR LABEL 1 GREEN 60 2 NOT USED 3 WHITE 51A 4 BLACK 51 ID COLOUR LABEL 1 GREEN 60 2 BLACK 52 3 WHITE 51A 4 RED 52A SECTION A A 1 2 3 4 SECTION B B 1 2 3 4 3 4 2 1 3 4 2 1 3 4 2 1 51A WHITE 51 BLACK 52A RED 51A WHITE 51 BLACK 60 GREEN 60 GREEN 52A RED 51A WHITE 52 BLACK 60 GREEN S51A S60 SCHEMATIC VIEW Upper Control Harness Platform Limit Switch Harness Lower Control...

Page 62: ...A B C D E F G H V Z Y X W 62 SJ30AJE SJ30ARJE 196274AF BLACK 01 01 3 14 Emergency Pump Base Controls Wiring M211083AA ...

Page 63: ...A B C D E F G H V Z Y X W 63 SJ30AJE SJ30ARJE 196274AF BLACK WIRE WHITE WIRE 09 17 3 15 Direction Sensing Limit Switch Base Control Wiring M211101AA ...

Page 64: ... SJ30ARJE 196274AF M211104AB RISER LIM IT SW ITC H MAIN BOOM LIMIT SWITCH FLY BOOM LIMIT SWITCH WHITE WIRE BLACK WIRE BLACK WIRE WHITE WIRE WHITE WIRE BLACK WIRE 09 59 29A 29 3 16 High Speed Cut Out Limit Switches Base Controls Wiring AB ...

Page 65: ...B C D E F G H V Z Y X W 65 SJ30AJE SJ30ARJE 196274AF M211100AA GREEN YELLOW WIRE 3 BLACK WIRE 1 BLACK WIRE 5 BLACK WIRE 4 BLACK WIRE 2 BLACK 60 82 118 162 02 3 17 Overload Sensor Platform Controls Wiring ...

Page 66: ...A B C D E F G H V Z Y X W 66 SJ30AJE SJ30ARJE 196274AF BLACK WIRE WHITE WIRE 04 8A M211102AA 3 18 Footswitch Platform Controls Wiring ...

Page 67: ...A B C D E F G H V Z Y X W 67 SJ30AJE SJ30ARJE 196274AF BLACK WIRE WHITE WIRE 04 PIN 7 M211103AA 3 19 SGE Platform Controls Wiring ...

Page 68: ...A B C D E F G H V Z Y X W 68 SJ30AJE SJ30ARJE 196274AF ...

Page 69: ...ACT V7 RV4 1500 PSI RB RA EB EA T2 POUT C1 STEER CYLINDER CB2 CACA LHN 3000 PSI 3 1 CB1 CACA LHN 3000 PSI 3 1 CB4 CBCA LIN 1000 PSI 3 1 CB3 CBCA LIN 1000 PSI 3 1 C2 MAIN BOOM LIFT CYLINDER C3 RISER CYLINDER C4 FLY BOOM EXTENSION CYLINDER RA1 TURRET ROTATION SWING DRIVE MOTOR MB2 PLATFORM CONTROL VALVE ASSEMBLY T P C7 MASTER CYLINDER C6 PLATFORM LEVELING SLAVE CYLINDER 4H 35 UP 4H 34 DOWN V8 4H 37 ...

Page 70: ...N 1000 PSI 3 1 C2 MAIN BOOM LIFT CYLINDER C3 RISER CYLINDER C4 FLY BOOM EXTENSION CYLINDER RA1 TURRET ROTATION SWING DRIVE MOTOR MB2 PLATFORM CONTROL VALVE ASSEMBLY T P C7 MASTER CYLINDER C6 PLATFORM LEVELING SLAVE CYLINDER 4H 35 UP 4H 34 DOWN V8 4H 37 RIGHT 4H 36 LEFT V9 4H 43 RIGHT 4H 42 LEFT V10 CB7 CBBB LHN 3000 PSI 1 5 1 CB8 CBBB LHN 3000 PSI 1 5 1 CB9 CACA LHN 3300 PSI 3 1 CB10 CACA LHN 3300...

Page 71: ... R3 R4 R11 R12 02 2A L 38B 2A 2C 2B 38B 34B 30B 30A 38A 34A 02 02 02 08 28A 82 04 02 R10 R2 02 2B 2C R1 R9 L 30B 34B PL6 04 BP3 118 02 118 82 D118 208CR1 28CR D20A 20B 20A 08 02 60 04 42 43 D08A 08B 7A 20B 23 24 60 28A 04 04B 04 02 04B 204CR 01A 118 82 60 162 43 42 41 40 37 36 35 34 08B 08A 08 04 04 02 02 02 02 08A D01 01 01A 04 01A La N Lb 02 04B 04B D R13 02 02 02 162 40B 02 28 D02 01 3B 3C 13 1...

Page 72: ...0B 30A 38A 34A 02 02 02 08 28A 82 04 02 R10 R2 02 2B 2C R1 R9 L 30B 34B PL6 04 BP3 118 02 118 82 D118 208CR1 28CR D20A 20B 20A 08 02 60 04 42 43 D08A 08B 7A 20B 23 24 60 28A 04 04B 04 02 04B 204CR 01A 118 82 60 162 43 42 41 40 37 36 35 34 08B 08A 08 04 04 02 02 02 02 08A D01 01 01A 04 01A La N Lb 02 04B 04B D R13 02 02 02 162 40B 02 28 D02 01 3B 3C 13 14 60 30 31 32 33 34 35 36 37 38 39 28 162 59B...

Page 73: ... R8 R3 R4 R11 R12 02 2A L 38B 2A 2C 2B 38B 34B 30B 30A 38A 34A 02 02 02 08 28A 82 04 02 R10 R2 02 2B 2C R1 R9 L 30B 34B PL6 04 BP3 118 02 118 82 D118 208CR1 28CR D20A 20B 20A 08 02 04 04 42 43 D08A 08B 7A 20B 23 24 04 28A 04 04B 04 204CR 01A 118 82 60 162 43 42 41 40 37 36 35 34 08B 08A 08 04 04 02 02 02 02 08A D01 01 01A 02 04B 04B D R13 02 02 02 162 40B 02 28 D02 01 3B 3C 13 14 60 30 31 32 33 34...

Page 74: ...9 60A 17 162 01C 02 02 60 8B 8B 02 BLACK WIRE FROM BEEPER RED WIRE FROM BEEPER MAIN MANIFOLD HARNESS 192101 CHARGER CUTOUT HARNESS 192111 RISER LOWERING HARNESS 192181 HARNESSES FROM MIDDLE STRAIN RELIEF ON SIDE OF BOX 60A 8B 60 02 D01 2 01 162C D162 1 162C 02 162C 30 30B 162CCR 162C D02 3 30B 59 D59 2 D01B 01B 01B 01B D01B 1 01 01B 60 10 30B CANH 7C CANL CANH 7C CANL 1 1 1 2 2 2 3 3 3 4 4 4 7A 3 ...

Page 75: ... 72 73 73 73 59 60A 17 162 01C 02 02 60 8B 8B 02 BLACK WIRE FROM BEEPER RED WIRE FROM BEEPER MAIN MANIFOLD HARNESS 192101 CHARGER CUTOUT HARNESS 192111 RISER LOWERING HARNESS 192181 HARNESSES FROM MIDDLE STRAIN RELIEF ON SIDE OF BOX 60A 8B 60 02 02 162C 30 30B 162CCR D162 1 162 162C 59 D59 2 162C D01 2 01 162C D02 3 30B D01B 1 01 01B 30B CANH CANL 7C CANL 7C CANH CANL 7C CANH 1 2 3 4 1 2 3 4 1 2 3...

Page 76: ...RNESSCONNECTIONDIAGRAM 8B 8B 02 MAIN MANIFOLD HARNESS 192101 60 59 D59 162B SPLICE _ 02 162B 01 01B 162BCR 01B P R N I 60 02 SPLICE 02 60A 30A 30 SPLICE 60ACR 162 D162 162B CHARGER CUTOUT HARNESS 192111 RISER LOWERING HARNESS 192181 02 60A 60 HARNESSESFROMMIDDLESTRAINRELIEFONSIDEOFBOX CAP1 59 D59 2 162C D02 3 02 162C D02 4 02 01B 02 01B 7B 01BCR 7A 02 162C 30 30B 162CCR D162 1 162 162C D01 2 01 16...

Page 77: ...0 8CCR 39 51C CR1 CR2 51CCR3 02 02 8B 51CCR4 8C SPLICE 51C CANH CANL 7C CANL CANH D7A 3 7C 1 7C 10 2 7C 2 7C CANL C01 HOURMETER 01D 7D 7C D7D D01 3 SPLICE 01DCR ADDRELAY FORT UNIT SPLICE 3B CANH CANL 01D 24 00 HM HM CANL CANH TORCONTR 192096 WIRE1 3D BLACK WIRE2 00 WHITE WIRE3 03 RED WIRE4 3C GREEN WIRE5 10 ORANGE WIRE7 D WHITE BLACK WIRE8 28 RED BLACK WIRE9 17 GREEN BLACK WIRE10 59 ORANGE BLACK W...

Page 78: ...SENSING DIRECTION 09 17 09 29 29A 59 LS2 RISER DN LS3 BOOM DN LS4 FLY IN N C N C N C 208 208 290 290 8B ENABLE S21 FUNCTION 10 10A 162 PL6 LOW BATTERY 290 04 04 204 04A 204 01A 31 59B 4 30B 30B 30B 23 23 23 24 24 24 D D D 70 70 70 208CR 208 60 9A 09 D10A D8A 8A 8B 10A 8B 02 02 3A 48 3C 48 SUPPR SUPPR 08 04A 01A 204CR 204 04 04 04B BEEPER BP4 SGE 02 04B LB4 SGE BEACON 02 04B 259 7A 60 59B 59B 59B 6...

Page 79: ... TRAY LEFT SIDE MAIN DISCONNECT LEFT MAIN DISCONNECT RIGHT FOOT S6 SWITCH 8A 04 POSITION 11 A POSITION 1 A POSITION 2 A POSITION 3 A POSITION 4 A POSITION 5 A POSITION 1 B POSITION 4 B POSITION 22 A POSITION 5 B POSITION 23 A POSITION 6 B POSITION 3 B POSITION 14 B POSITION 7 B POSITION 8 B POSITION 15 B POSITION 16 B POSITION 9 B POSITION 9 A POSITION 10 A POSITION 24 A POSITION 7 A POSITION 6 A ...

Page 80: ...SING DIRECTION 09 17 09 29 29A 59 LS2 RISER DN LS3 BOOM DN LS4 FLY IN N C N C N C 208 208 290 290 8B ENABLE S21 FUNCTION 10 10A 162 PL6 LOW BATTERY 290 04 04 204 04A 204 01A 31 59B 4 30B 30B 30B 23 23 23 24 24 24 D D D 70 70 70 208CR 208 60 9A 09 D10A D8A 8A 8B 10A 8B 02 02 3A 48 3C 48 SUPPR SUPPR 08 04A 01A 204CR 204 04 04 04B BEEPER BP4 SGE 02 04B LB4 SGE BEACON 02 04B 259 7A 60 59B 59B 59B 60 6...

Page 81: ...A 8B 02 02 3A 48 3C 48 SUPPR SUPPR 08 04A 01A 204CR 204 04 04 04B BEEPER BP4 SGE 02 04B LB2 SGE BEACON 02 04B 259 7A 60 59B 59B 59B 60 60 7A 7A 259CR 162CR 02 162 10B 10 02 162A 10 PL7 OVERLOAD 02 162A 6 40B D13 13 72 D39 39 71 D38 38 72 73 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 ...

Page 82: ...R CONVERTER 48V TO 12 V NEGATIVE POSITIVE 12V 3D 00 00 3D 3D 8B 8B 3E 59 208 224 3C 223 CONTACTOR GROUND ENCODER B D 24 23 10 THERMAL ENCODER 90 CAN L STEER SENSOR 17 28 259 7A 8B 3D BRAKE ENCODER 60A 3C 204 ENCODER B ENCODER A 70 01A 04A 162 71 THERMAL ENCODER CAN L 30A 128 72 73 01A 208 59 17 28 28 RM 2 RM 3 RM 4 RM 5 RM 6 RM 7 RM 8 RM 9 RM 10 RM 11 RM 12 RM 13 RM 14 RM 15 RM 16 RM 17 RM 18 RM 1...

Page 83: ...al cannot cover all possible troubles and deficiencies that may occur If a specific trouble is not listed isolate the major component in which the trouble occurs isolate whether the problem is electrical or hydraulic and then isolate and correct the specific problem The content of this section is separated into probable cause and remedy The information preceded by a number represents the probable ...

Page 84: ... left motor controller pin LM7 Check continuity Replace if defective 10 Loose or broken wire 48 from motor contactor 3CCR to diode D48 Check continuity Replace if defective 11 Open or defective diode D48 Check diode Replace if defective 12 Loose or broken wire 48 from diode D48 to fuse F1 Check continuity Replace if defective 13 Defective fuse F1 10Amp Check fuse Replace if defective 14 Loose or b...

Page 85: ...ontroller pin LM10 and contactor 3CCR Check continuity Replace if defective 27 No negative output from right motor controller pin RM12 to contactor 3CCR Check continuity Replace if defective 28 Defective contactor 3CCR Check contactor Replace if defective 29 Defective main fuse F3 or F4 400Amp Check fuse Replace if defective 30 Defective DC DC converter Check continuity Replace if defective 31 Loo...

Page 86: ...86 Check continuity Replace if defective 6 Loose or broken wire 7C from diode s D7A and or D10 to 01DCR pin 30 Check continuity Replace if defective 7 Loose or broken wire 01D from telematics pin 9 to 01DCR pin 85 Check continuity Replace if defective 8 If telematics device is not installed loose broken or missing Jumper JMPR1 from 57DCR pin 85 to ground 00 Check continuity Replace if defective or...

Page 87: ... 5 to right motor controller pin RM20 Check continuity Replace if defective 4 Loose or broken wire 10 from right motor controller pin RM20 to diode D10 in tilt switch harness Check continuity Replace if defective 5 Open or defective diode D10 Diode is in tilt switch harness close to the tilt switch Check diode Replace if defective 6 Loose or broken wire 60 from diode D10 in tilt switch harness to ...

Page 88: ...switch while activating up function between wires 10A and 14 Replace switch if no continuity found 3 Loose or broken wire 14 from boom switch S20 to base terminal block Check continuity Replace if defective 4 Open or defective diode D14 Check diode Replace if defective 5 Loose or broken wire 71 from base terminal block to motor control harness A Check continuity Replace if defective 6 Loose or bro...

Page 89: ...wire 13 from main manifold harness plug pin 1 to boom down valve 4H 13 Check continuity Replace if defective 9 Loose or broken wire 02 from main manifold harness plug to boom down valve 4H 13 Check continuity Replace if defective 10 Defective boom down coil 4H 13 Check continuity and resistance through coil Replace if defective 4 2 7 All Controls Inoperative 1 Loose or broken wire 10A from enable ...

Page 90: ... wire 30A from riser switch S18 to relay 60ACR Check continuity Replace if defective 5 Loose or broken wire 30 from relay 60ACR to base terminal block Check continuity Replace if defective 6 Defective relay 60ACR Check relay Replace if defective 7 Loose or broken wire 30 from base terminal block to relay 162CCR Check continuity Replace if defective 8 Loose or broken wire 162C from diodes D162 1 an...

Page 91: ...nuity Replace if defective 8 Loose or broken wire 32 from main manifold harness plug pin 7 to rotate left valve 5H 32 Check continuity Replace if defective 9 Loose broken wire 02 from main manifold harness plug to rotate left valve 5H 32 Check continuity Replace if defective 10 Defective rotate left coil 5H 32 Check continuity and resistance through coil Replace if defective 4 2 10 No Turret Rotat...

Page 92: ...vating retract function between wires 10A and 38 If no continuity found replace switch 3 Loose or broken wire 38 from telescope switch S17 to base terminal block Check continuity Replace if defective 4 Open or defective diode D38 Check diode Replace if defective 5 Loose or broken wire 72 from base terminal block to motor control harness A Check continuity Replace if defective 6 Loose or broken wir...

Page 93: ... to telescope extend valve 4H 39 Check continuity Replace if defective 9 Loose or broken wire 02 from main manifold harness plug to telescope extend valve 4H 39 Check continuity Replace if defective 10 Defective telescope retract coil 4H 39 Check continuity and resistance through coil Replace if defective 4 2 13 No Platform Rotate Left from Base Control Console 1 Loose or broken wire 10A from enab...

Page 94: ... continuity found replace switch 3 Loose or broken wire 37 from platform rotate switch S14 to base terminal block Check continuity Replace if defective 4 Open or defective diode D37 Check diode Replace if defective 5 Loose or broken wire 73 from base terminal block to motor control harness A Check continuity Replace if defective 6 Loose or broken wire 73 from motor control harness A pin 22 to left...

Page 95: ... control harness A pin 21 to left motor controller pin LM31 Check continuity Replace if defective 7 Loose or broken wire 35 from base control block to platform plug A pin 17 in base control console Check continuity Replace if defective 8 Loose or broken wire 35 in boom cable A or its connectors Check for continuity between pins 17 on cable A Check for loose or corroded connections on cable connect...

Page 96: ...wire 73 from motor control harness A pin 22 to left motor controller pin LM32 Check continuity Replace if defective 7 Loose or broken wire 34 from base control block to platform plug A pin 16 in base control console Check continuity Replace if defective 8 Loose or broken wire 34 in boom cable A or its connectors Check for continuity between pins 16 on cable A Check for loose or corroded connection...

Page 97: ...roken wire 73 from motor control harness A pin 22 to left motor controller pin LM32 Check continuity Replace if defective 7 Loose or broken wire 43 from base control block to platform plug B pin 13 in base control console Check continuity Replace if defective 8 Loose or broken wire 43 in boom cable B or its connectors Check for continuity between pins 13 on cable B Check for loose or corroded conn...

Page 98: ...broken wire 73 from motor control harness A pin 22 to left motor controller pin LM32 Check continuity Replace if defective 7 Loose or broken wire 42 from base control block to platform plug B pin 12 in base control console Check continuity Replace if defective 8 Loose or broken wire 42 in boom cable B or its connectors Check for continuity between pins 12 on cable B Check for loose or corroded con...

Page 99: ...fold harness plug pin 12 to platform level up valve 4H 41 Check continuity Replace if defective 9 Loose or broken wire 02 from main manifold harness plug to platform level up valve 4H 41 Check continuity Replace if defective 10 Defective platform level up coil 4H 38 Check continuity and resistance through coil Replace if defective 11 Loose or broken wire 10A from ignition pump switch S5 to platfor...

Page 100: ...e D40 Check diode Replace if defective 5 Loose or broken wire 73 from base terminal block to motor control harness A Check continuity Replace if defective 6 Loose or broken wire 73 from motor control harness A pin 22 to left motor controller pin LM32 Check continuity Replace if defective 7 Loose or broken wire 40 from base terminal block to main manifold harness pin 11 Check continuity Replace if ...

Page 101: ...ntrol console Check continuity Replace if defective 9 Loose or broken wire 8B in boom cable B or its connectors Check continuity Replace if defective 10 Loose or broken wire 8B from plug B pin 5 to base terminal block Check continuity Replace if defective 11 Loose or broken wire 8B from base terminal block to motor control harness A Check continuity Replace if defective 12 Loose or broken wire 8B ...

Page 102: ...ce 6 No output on pin 22 of the valve driver to wire 14 Check pin 22 for minimum 7 volts If no voltage present with foot on footswitch check section 5 for OCM pin voltage reference 7 Loose or broken wire 14 from valve driver pin 22 to plug A pin 7 in platform control console Check continuity Replace if defective 8 Loose or broken wire 14 in boom cable A or its connectors Check for continuity betwe...

Page 103: ... pin 8 for minimum 5 5 volts If no voltage present with foot on footswitch check section 5 for OCM pin voltage reference 7 Loose or broken wire 13 from valve driver pin 8 to plug A pin 6 in platform control console Check continuity Replace if defective 8 Loose or broken wire 13 in boom cable A or its connectors Check for continuity between pins 6 on cable A Check for loose or corroded connections ...

Page 104: ...tage present with foot on footswitch check section 5 for OCM pin voltage reference 8 No output on pin 23 of the valve driver to wire 20A Check pin 10 for minimum 4 5 volts If no voltage present with foot on footswitch check section 5 for OCM pin voltage reference 9 Loose or broken wire 31 from valve driver pin 10 to plug A pin 13 in platform control console Check continuity Replace if defective 10...

Page 105: ...e valve driver to wire 30C Check pin 19 for minimum 6 2 volts If no voltage present with foot on footswitch check section 5 for OCM pin voltage reference 9 Loose or broken wire 30C from valve driver pin 19 to relay 204CR1 Check continuity Replace if defective 10 Defective N C contacts in relay 204CR1 Check continuity between wires 30C and 30 Replace if continuity not found 11 Loose or broken wire ...

Page 106: ...nal voltage If no voltage present with foot on footswitch check section 5 for OCM pin voltage reference 6 No output on pin 20 of the valve driver to wire 32 Check pin 20 for minimum 6 2 volts If no voltage present with foot on footswitch check section 5 for OCM pin voltage reference 7 Loose or broken wire 32 from valve driver pin 20 to plug A pin 14 in platform control console Check continuity Rep...

Page 107: ...35 for minimum 6 9 volts If no voltage present with foot on footswitch check section 5 for OCM pin voltage reference 7 Loose or broken wire 33 from valve driver pin 35 to plug A pin 15 in platform control console Check continuity Replace if defective 8 Loose or broken wire 33 in boom cable A or its connectors Check for continuity between pins 15 on cable A Check for loose or corroded connections o...

Page 108: ...m speed control If no voltage present with foot on footswitch check section 5 for OCM pin voltage reference 8 No output on pin 21 of the valve driver to wire 38 Check pin 21 for 12 volts If no voltage present with foot on footswitch check section 5 for OCM pin voltage reference 9 Loose or broken wire 38 from valve driver pin 21 to plug A pin 20 in platform control console Check continuity Replace ...

Page 109: ... speed control If no voltage present with foot on footswitch check section 5 for OCM pin voltage reference 8 No output on pin 11 of the valve driver to wire 39 Check pin 11 for 12 volts If no voltage present with foot on footswitch check section 5 for OCM pin voltage reference 9 Loose or broken wire 39 from valve driver pin 11 to plug A pin 21 in platform control console Check continuity Replace i...

Page 110: ...ck continuity Replace if defective 8 Defective rotate left valve coil 4H 36 Check continuity and resistance through coil Replace if defective 4 2 31 No Platform Rotate Right from Platform Control Console 1 Loose or broken wire 08 from platform terminal block to platform rotate switch S11 Check continuity Replace if defective 2 Defective platform rotate switch S11 Check continuity through switch wh...

Page 111: ...e This voltage varies with the A3 boom speed control If no voltage present with foot on footswitch check section 5 for OCM pin voltage reference 8 No output on pin 5 of the valve driver to wire 35 at the platform terminal block Check pin 5 for 12 volts If no voltage present with foot on footswitch check section 5 for OCM pin voltage reference 9 Loose or broken wire 35 or 02 from platform terminal ...

Page 112: ...l Replace if defective 4 2 34 No Jib Rotate Left from Platform Control Console 1 Loose or broken wire 08 from platform terminal block to jib rotate switch S10 Check continuity Replace if defective 2 Defective jib rotate switch S10 Check continuity through switch while activating rotate left function between wires 08 and 42 3 Loose or broken wire 42 from jib rotate switch S10 to platform terminal b...

Page 113: ... Check diode Replace if defective 5 Loose or broken wire 42A from platform terminal block to valve driver pin 15 Check for 12 volts at pin 15 Check continuity Replace if defective 6 No output on pin 23 of the valve driver to wire 20A Check pin 23 for proportional voltage This voltage varies with the A3 boom speed control If no voltage present with foot on footswitch check section 5 for OCM pin vol...

Page 114: ...A Check pin 23 for proportional voltage This voltage varies with the A3 boom speed control If no voltage present with foot on footswitch check section 5 for OCM pin voltage reference 7 Loose or broken wire 41 from platform terminal block to plug B pin 11 in platform control console Check continuity Replace if defective 8 Loose or broken wire 41 in boom cable B or its connectors 9 Loose or broken w...

Page 115: ...ortional voltage This voltage varies with the A3 boom speed control If no voltage present with foot on footswitch check section 5 for OCM pin voltage reference 7 Loose or broken wire 40 from platform terminal block to plug B pin 10 in platform control console Check continuity Replace if defective 8 Loose or broken wire 40 in boom cable B or its connectors Check for continuity between pins 10 on ca...

Page 116: ...erminal block to drive joystick A1 Check continuity Replace if defective 2 Loose or broken wire 02 from platform terminal block to drive joystick A1 Check continuity Replace if defective 4 2 40 No Forward Drive 1 No output on D when forward is selected on drive joystick A1 See drive joystick test procedure in section 5 2 Loose or broken wire D signal from drive joystick A1 to plug A pin 24 in plat...

Page 117: ...d and horizontal or below 1 Loose or broken wire 09 from base terminal block to limit switch LS2 Check continuity Replace if defective 2 Open or defective limit switch LS2 Ensure boom is horizontal or below and fully retracted Adjust switch if required Check continuity through switch Replace if required 3 Loose or broken wire 29 from limit switch LS2 to base terminal block Check continuity Replace...

Page 118: ...e A or its connectors Check for continuity between pins 10 on cable A Check for loose or corroded connections on cable connectors Replace if wire is defective 3 Loose or broken wire 24 from base plug A pin 10 to motor control harness A Check continuity Replace if defective 4 Loose or broken wire 24 from motor control harness A pin 13 to right motor controller pin RM19 Check continuity Replace if d...

Page 119: ...defective 7 Loose or broken wire 7A from base terminal block to main manifold harness Check continuity Replace if defective 8 Loose or broken wire 223 or 7A from main manifold harness to right steer valve 4H 223 Check continuity Replace if defective 9 Defective right steer valve coil 4H 223 Check continuity and resistance through coil Replace if defective 4 2 45 Direction Sensing Inoperative 1 Loo...

Page 120: ...Repair or replace valve as required 6 System pump P1 defective Test pump with flow meter Replace if defective 4 3 2 No Main Boom Up 1 Stuck or defective lift up valve 4H 14 Clean valve Check operation of valve Repair or replace valve as required 2 Stuck or defective counterbalance valve CB1 or CB2 Clean valve Check O rings on valve Repair or replace valve as required 3 Defective lift cylinder C2 C...

Page 121: ... Down 1 Stuck or defective riser down valve 2H 30 Clean valve Check operation of valve Repair or replace valve as required 2 Plugged or defective orifice OR5 Check orifice Replace if plugged or defective 4 3 6 No Turret Rotate Left 1 Stuck or defective rotate left valve 5H 32 Clean valve Check operation of valve Repair or replace valve as required 2 Stuck or defective relief valve RV3 Set valve to...

Page 122: ... valve Check operation of valve Repair or replace valve as required 2 Stuck or defective boom retract valve 4H 38 Clean valve Check operation of valve Repair or replace valve as required 3 Stuck or defective counterbalance valve CB3 or CB4 Clean valve Check O rings on valve Repair or replace valve as required 4 Defective extension cylinder C4 Check seals on cylinder Replace as necessary Replace cy...

Page 123: ...eplace valve as required 2 Plugged or defective orifice OR3 Check orifice Replace if plugged or defective 3 Stuck or defective rotate right valve 4H 37 Clean valve Check operation of valve Repair or replace valve as required 4 Stuck or defective counterbalance valve CB9 or CB10 Clean valve Check O rings on valve Repair or replace valve as required 5 Defective rotary actuator RA2 Check actuator Rep...

Page 124: ...n valve Check O rings on valve Repair or replace valve as required 5 Defective rotary actuator RA3 Check actuator Repair or replace as necessary 4 3 15 No Jib Rotation Left 1 Stuck or defective flow enable valve 2H 20A Clean valve Check operation of valve Repair or replace valve as required 2 Plugged or defective orifice OR4 Check orifice Replace if plugged or defective 3 Stuck or defective rotate...

Page 125: ...alve as required 7 Defective leveling cylinder C7 or slave cylinder C6 Check seals on cylinder Replace as necessary Replace cylinder if defective 4 3 17 Platform will not Level Up Manually 1 Plugged or defective orifice OR1 Check orifice Replace if plugged or defective 2 Stuck or defective platform level up valve 4H 41 Clean valve Check operation of valve Repair or replace valve as required 3 Stuc...

Page 126: ...e Repair or replace valve as required 2 Defective steer cylinder C1 Check seals on cylinder Replace as necessary Replace cylinder if defective 4 3 19 No Right Steer 1 Stuck or defective right steer valve 4H 223 Clean valve Check operation of valve Repair or replace valve as required 2 Defective steer cylinder C1 Check seals on cylinder Replace as necessary Replace cylinder if defective ...

Page 127: ... resistor R13 for 680 ohms 4 4 4 Load Cell red Alarm LED is OFF with platform overloaded 1 Open safety contact circuit Check for connections with wires 60 and 162 at platform terminal block and base terminal block Check resistor R13 for 680 ohms 4 4 5 Platform Indicator Light does not turn ON 1 Defective lamp Check lamp Replace if defective 2 Defective load cell Defective if 0V is measured between...

Page 128: ...128 SJ30AJE SJ30ARJE 196274AF Notes ...

Page 129: ...y procedure 1 Park the mobile elevating work platform MEWP on a firm level surface 2 Retract and lower the boom riser and platform until the MEWP is in the stowed position 3 Pull out the emergency stop buttons on the base controls and on the platform controls 4 Turn the keyswitch to the off position 5 Disconnect one of the battery connectors After completing any procedure which involves modifying ...

Page 130: ...ing UP and DOWN resets the HMI to menu screen 0 5 2 Platform 5 2 1 Human Machine Interface HMI Maintaining proper calibration is essential for the good performance of the MEWP To access the SCM console open the platform control cover The SCM has an integrated multi segment two line display with membrane keys that allow it to be used as the main interface to system controls and adjustments The Huma...

Page 131: ... 1345AA Function Attribute THRESH Threshold RAMPDN Ramp Down RAMPUP Ramp Up LOWRNG Low Range MAXOUT Maximum Output SCM Function Channel Names FLOW ENABLE Fn01A Flow Enable RISER DN 2A Fn05A Riser Down RISER UP 2B Fn05B Riser Up BOOM DOWN Fn03A Main Boom Down BOOM UP Fn03B Main Boom Up ROTATE L Fn04A Turret Rotate Left ROTATE R Fn04B Turret Rotate Right ...

Page 132: ...AI 7 0 5V to 8 5V Jib Elevation Switch Resistors Input Digital Expected Value Description DI 1 0 or 1 Jib Rotate Common DI 3 0 or 1 Platform Rotate Common DI 4 0 or 1 Platform Level Common DI 5 0 or 1 Master Enable DI 11 0 or 1 Stowed Limit Output Digital Expected Value Description DOUT 1 0 or 1 Riser Down Active DOUT 2 0 or 1 Jib Up Valve DOUT 3 0 or 1 Platform Level Allowed DOUT 4 0 or 1 Jib Dow...

Page 133: ...RTING SCREEN ENTER PASSWORD 0 0 FLASHING SET PMU MOD PCT PRESS SELECT FLASHING ENTER PASSWORD 7 7 FLASHING ENTER PASSWORD 70 0 FLASHING ENTER PASSWORD 75 5 FLASHING ENTER PASSWORD 750 0 FLASHING ENTER PASSWORD 755 5 FLASHING SETUP UNLOCKED PRESS OR FLASHING MODE XX XX LTD FUNCTIONS OFF 5X 5X 7X MENU SELECT MENU SELECT MENU SELECT MENU SELECT SAVE EXIT CE AS Models ANSI CSA KC Models OR MENU SELECT...

Page 134: ...b Down 15 27 Boom Down 15 50 NOTE 1 Recycle power to the OCM with the e stop to re enable the password protection 2 If the OCM is inactive for more than 5 minutes the password must be re entered 1216AB Motor Speeds SET PMU MOD PCT PRESS SELECT FLASHING JIB ROT FNCT MAX FLASHING Increases Value TOGGLE JIB ROTATE FNCT FLASHING PLAT ROT FNCT FLASHING JIB ROT FNCT MIN FLASHING Once the value has been ...

Page 135: ... Speed This page is to adjust the THRESHOLD MAX OUT LOW RANGE RAMP UP RAMP DOWN for FLOW ENABLE RISER DOWN RISER UP BOOM DOWN BOOM UP TURRET LEFT TURRET RIGHT Output PWM Expected Valve Description Flow Enable Riser Down MODE 30E FUNCTIONS OFF DISPLAYED Increases Value TOGGLE ADJUST FLASHING FLOW ENAB THRESH Fn01A VALUE FLASHING RISER DN THRESH Fn01B VALUE FLASHING RISER UP THRESH Fn02A VALUE BOOM ...

Page 136: ...controller Riser active signal Gravity down Test between pin 4 and 02 wire Pin 5 12 volt output on wire 35 to jib up valve 4H 35 Test between pin 5 and 02 wire while operating jib up Pin 6 12 volt output on wire 40B to platform level switch S12 no output if operating another boom function Test between pin 6 and 02 wire Pin 7 12 volt output on wire 34 to jib down valve 4H 34 Test between pin 7 and ...

Page 137: ...19 Riser down selected Proportional output on wire 30 to riser down valve 4H 30 0 volts to 8 9 volts depending on boom speed control potentiometer position Threshold 6 2 volts Test between pin 19 and 02 wire Pin 20 Turret rotate left selected Proportional output on wire 32 to turret rotate left valve 4H 32 0 volts to 11 2 volts depending on position of joystick Threshold 6 2 volts Test between pin...

Page 138: ...ast speed Test between pin 30 and 02 wire while operating jib telescope or platform rotate junctions Pin 31 Drive Boom function Enable 12 volt input on wire 59B Machine stowed and tilted Boom up riser up and telescope out functions allowed until limit switches are activated LS2 LS3 or LS4 Drive remains active Machine elevated and tilted All boom functions remain active Drive is cut out Test betwee...

Page 139: ...n 4 2 4 9 Volts Right 4 9 8 5 Volts full stroke Left 4 1 0 5 Volts full stroke Boom Elevation Y axis Neutral Position 4 2 4 8 Volts Up 4 9 8 5 Volts full stroke Down 4 1 0 5 Volts full stroke 12 Volts Volts Drive A1 Controller Drive Forward 04 YEL POWER RED 02 WHT GROUND BLK Pin 24 BLK D SIGNAL YEL Pin 10 24 BLU BLK LEFT WHT RED Pin 9 23 BLK WHT RIGHT WHT YEL PLUG A Drive Reverse Reference Analog ...

Page 140: ...ws the Telescopic Switch Voltage Divider Circuit 7 25V WIRE L GND O2 WIRE L GND O2 TELESCOPE IN TELESCOPE OUT 250 OHMS 250 OHMS R5 R6 R7 R8 250 OHMS 250 OHMS P1 32 FLY TOGGLE SWITCH WIRE 38A P1 32 WIRE 38A PIN 32 4 83V 7 25V TELESCOPE IN TELESCOPE OUT 250 OHMS 250 OHMS R5 R6 R7 R8 250 OHMS 250 OHMS FLY TOGGLE SWITCH PIN 32 2 41V ...

Page 141: ...egulated by applicable safety standards for Mobile Elevated Work Platforms Load Cell LED Display Error LED Alarm LED Interface Connector Zero Tare LED Power LED T Label 4 Button Teach in Handset Service only Platform Control Console Indicator Module Overload Light Bottom View of Deck MEWP Rotary Actuator Mount External Bolts Load Cell Permanent Bolts Deck Error LED Continously on when there is a s...

Page 142: ...ull out both emergency stops 4 Turn the keyswitch to the base position 5 Activate the enable switch Result The overload indicator light and audible alarm pulses two times 6 Ensure the platform is unloaded and is free from any surface contact Result The green power LED flashes the orange LED is ON the red alarm LED is OFF and the red error LED is OFF 7 Place a 244 kg 538 lb load on the platform Res...

Page 143: ...ower is on and the handset is properly connected WARNING Do not disconnect the handset at any point of the following steps until instructed to do so 8 On the Teach in handset depress the 4 button for four seconds Result The T label on the handset lights up constantly 9 Add a test load of 244 kg 538 lb onto the center of the platform 10 Depress the 4 button for four seconds Result The T label on th...

Page 144: ... boom to a comfortable working height chest high and the extend fly boom until the wear pads are accessible 3 Loosen the wear pad fasteners 4 Shim the wear pads as necessary to obtain zero to 0 8 mm 1 32 clearance and zero drag Fly Boom Shim 1 32 Feeler Gauge Wear Pad 5 Extend and retract the fly boom through the entire range of motion and observe for loose points NOTE Always maintain squareness b...

Page 145: ...inder hoses x4 indicating where they are connected to the cylinder Front Back 5 Disconnect the hoses one by one being sure to plug the hoses and cap the fittings size 04 6 Remove the bolt washer and keeper pin securing the upper cylinder pin 7 Use a rubber coated mallet and driver to tap out the cylinder s upper pin 8 Remove the pin 9 Pull the top of the cylinder back toward the knuckle 10 Remove ...

Page 146: ...e enough clearance for the master cylinder s lower pin to be removed 18 Repeat steps 14 through 17 with the opposite pin There will be more pressure on this pin so use the lifting device to adjust the boom slightly as needed to make the pin easier to remove 19 Lift the riser until the lower master cylinder pin is accessible 20 Remove the screw securing the pin then use a driver and mallet to tap o...

Page 147: ...l of the way down then raise it back up slightly to take the pressure off of the temporary knuckle pins 28 Remove the bolt and washer holding one of the temporary pins and remove the pin 29 Set the original pin back in place and start tapping it in with a mallet making sure the shims between the knuckle and arm are aligned while tapping the pin in 30 Use a large adjustable wrench on the pin flange...

Page 148: ...h the pin holes use the riser lift lower and or platform up down functions to help align the holes and tap the original pin back in Reinstall the keeper pin bolt and washer applying Loctite 242 to the bolt before installing it 36 Remove the oil pan and clean up any leaked oil 37 Remove the sling from the fly boom 38 Raise the boom to provide clearance then use the platform level switch on the base...

Page 149: ...que wrench to 47 Nm 35 ft Ib and tighten the mounting bolts with the same sequence 5 Torque the center bolt to 1044 Nm 770 ft lb 5 4 6 Platform Rotary Actuator Bolt Torque Sequence 1 Park the MEWP on a firm level surface in the stowed position 2 Disconnect one of the main power connectors 3 Set the torque wrench to 23 Nm 17 ft Ib and tighten the mounting bolts in a criss cross pattern sequence 1 2...

Page 150: ...ter Replacement 1 Turn the MEWP off 2 Place a suitable container under the filter 3 Use a filter wrench to remove the filter from the head Throw out the filter 4 Apply hydraulic oil to the o ring on the new filter and screw the filter into place 5 Tighten the filter with the filter wrench NOTE Refer to your national local regulations on how to dispose of used filters and oil NOTE Samples of hydrau...

Page 151: ... increase the pressure and counterclockwise to decrease the pressure until 217 bar 3150 psi is observed on the gauge 8 Tighten the lock nut 5 5 4 Main Pump Relief Valve Adjustment RV5 1 Locate test port GP on the main manifold and connect a 350 bar 5000 psi pressure gauge to it GP 2 Pull out the base and platform e stops 3 From the base controls use the telescope retract switch to activate the pre...

Page 152: ...sure and counterclockwise to decrease the pressure until 228 bar 3300 psi is observed on the gauge 8 Tighten the lock nut 5 5 6 Turret Rotate Relief Valve Adjustment RV3 1 Locate test port GP on the main manifold and connect a 350 bar 5000 psi pressure gauge to it GP RV3 2 Pull out the base and platform e stops 3 Raise the jib to ensure the platform will not contact the ground 4 Rotate the turret ...

Page 153: ...se to increase pressure and counterclockwise to decrease pressure until 3250 psi is observed on the gauge 9 Tighten the lock nut 5 5 8 Boom Extend Relief Valve Adjustment RV4 1 Locate test port GP on the main manifold and connect a a 5000 psi pressure gauge to it GP RV4 2 Pull out the base and platform e stops 3 Raise the jib to ensure the platform will not contact the ground 4 Fully retract the b...

Page 154: ...o increase pressure and counterclockwise to decrease pressure until 210 bar 3050 psi is observed on the gauge 9 Tighten the lock nut 5 6 Base 5 6 1 Battery Replacement 1 Disconnect the main power connector by pulling the red handle straight back 2 Pull the latch knob to unlock the battery tray Swing the tray out 3 Remove the wingnuts securing the battery tray lid one on each end and remove the lid...

Page 155: ...0 ft lb and tighten the inner gear mounting bolts in a criss cross pattern sequence 5 Repeat with the torque wrench set to 115 Nm 85 ft lb 6 Repeat with the torque wrench set to 230 Nm 170 ft lb 7 Repeat the previous steps with the outer lower gear mounting bolts 1 14 16 9 3 17 7 12 15 2 10 6 13 8 18 4 5 11 12 1 8 9 13 17 3 7 11 15 19 2 6 18 14 10 5 4 16 5 6 3 Check Torque Hub Oil Level 1 Drive th...

Page 156: ... mount 7 Install the new switch onto the mount and connect the switch plug to the 4 pin connector NOTE The tilt circuit is only powered when the controls are powered up 8 Turn the main disconnect switch to the ON position 9 Turn the base off platform key switch to the base position 10 Pull out both emergency stop buttons 11 Verify the switch is powered the red or green LED will be continually blin...

Page 157: ... the MEWP is parked on a firm level surface 2 Fully lower the platform and retract the fly boom 3 Chock or block the wheels to keep the MEWP from rolling forward or backward NOTE The tilt circuit is only powered when the controls are powered up 4 Connect the main power connectors 5 Pull out both emergency stop buttons 6 Turn the base off platform key switch to the base position 7 Verify the switch...

Page 158: ...ts The switch is verifying the new zero position Red LED Green LED Red LED Green LED i The green LED turns on solid Results The switch is ready for normal operation Red LED Green LED 9 Disconnect one of the main power connectors 10 Push in the emergency stop buttons 11 Remove the chock or wheel blocks 12 Proceed to Test and Verify Tilt Circuit Verify the Tilt Circuit Red LED Green LED Indicator Li...

Page 159: ...m current 50 85 C 90 C 95 C 105 C T C Imax Ambient Temperature Resistance ohm C F Min Typ Max 40 40 340 359 379 30 22 370 391 411 20 4 403 424 446 10 14 437 460 483 0 32 474 498 522 10 50 514 538 563 20 68 555 581 607 25 77 577 603 629 30 86 599 626 652 40 104 645 672 700 50 122 694 722 750 60 140 744 773 801 70 158 797 826 855 80 176 852 882 912 90 194 910 940 970 100 212 970 1000 1030 110 230 10...

Page 160: ...in 6 Platform Mode input 12 volt input on wire 7A Platform control mode Test for 12 volts between pin 6 and battery negative while in Platform position Pin 7 Accelerator input Wire D from drive joystick controller Neutral position 4 2 volts to 4 8 volts Forward function 4 9 volts to 8 5 volts Reverse function 4 1 volts to 5 volts Test between pin 7 and 02 wire Pin 8 Tilt sensor output to tilt rela...

Page 161: ...Test pin 16 for negative while operating right steer Platform must be over drive axle Pin 17 Variable negative output on wire 90 to battery condition light PL4 No light Charged Solid light Warning Blinking light Limp mode Test for negative at pin 17 Pin 18 12 volt input from platform Load cell on wire 162 12 volts within platform capacity 0 volts overload Test for continuity between pin 18 and bat...

Page 162: ...s remain active Drive is cut out Test for negative at pin 1 while machine is stowed Pin 2 12 volt output on wire 60 from diodes D7A or D10 Test for 12 volts between pin 2 and battery negative Pin 3 SGE input 12 volt input on wire 04A from SGE sensor bar SGE sensor bar active for less than 1 second Functions automatically return SGE sensor bar active for more than 1 second Reset is required Test be...

Page 163: ...ve at right motor encoder connector Replace if defective RM 6 12 volt input through motor controller harness A pin A10 from LS2 riser LS3 boom elevation limit switches and LS4 telescope limit switch on wire 59 12 volts full speed 0 volts creep speed one or more limit switches open Test for 12 volts at RM6 and battery negative while in drive mode and boom fully stowed RM 7 Not used RM 8 Negative ou...

Page 164: ... RM 16 and battery negative while operating left steer RM 17 Not used RM 18 Not used RM 19 12 volt input on wire 23 from right steer switch Test between RM 19 and battery negative while operating right steer RM 20 Base Mode input 12 volt input on wire 10 Base control mode Test for 12 volts between RM 20 and battery negative while in Base position RM 21 Not used RM 22 Thermal sensor input Refer to ...

Page 165: ...etween RM 35 and battery negative while in Platform position Left Motor Controller Connector LM 1 Enable in 12 volt input on wire 8B from motor controller harness A pin A12 Test between LM 1 and battery negative while activating footswitch or base enable switch LM 2 Not used LM 3 12 volt input on wire 3D from DC DC converter Test between LM 3 and battery negative with both upper and lower E stop s...

Page 166: ... 17 SGE input 12 volt input through motor controller harness B pin B3 on wire 04A from SGE sensor bar SGE sensor bar active for less than 1 second Functions automatically return SGE sensor bar active for more than 1 second Reset is required Test between LM 17 and battery negative while pressing sensor bar LM 18 Not used LM 19 12 volt input through motor controller harness A pin A18 from platform L...

Page 167: ...se speed 2 input on wire 72 50 of pump speed Test continuity on wire 72 between LM 31 and base terminal block LM 32 Base speed 3 input on wire 73 8 of pump speed Test continuity on wire 73 between LM 32 and base terminal block LM 33 Not used LM 34 Not used LM35 SGE reset 12 volt input through motor controller harness B pin B4 on wire 01A from SGE reset switch S25 Emergency controls also provides r...

Page 168: ... code Decoding the Alarms Displayed on the MDI CAN The format of the string shown on the display below is XXAYY where XX and AYY represent the alarmed node and the alarmed code respectively The First two digits represent the Node of the Controller where the Alarm is present For SJ30AJE ARJE this will be 03 for the right traction controller and 04 for the left traction controller The Final two digi...

Page 169: ...ory reset Clear Eeprom 3 Hardware problem in logic circuit card for high current overload protection Internal issue Replace controller 0XA26 SENS KO The current sensor is damaged 1 Cycle keyswitch 2 Factory reset Clear Eeprom 3 One of the current sensor used to measure the value on the motor phases is damaged Internal issue Replace controller 0XA27 PHASE KO One of the phases on the drive motors is...

Page 170: ...ck Motor connections Make sure motor phases windings cables do not have leakages towards chassis If no problems are found on the motor cables the problem is inside the controller Replace controller 0XA40 AUX DRIV SHRT Mos for electric brake is shorted 1 Cycle keyswitch 2 Check for short or low impedence to electric brakes 3 Replace controller that shows the fault 0XA41 WRONG SET BAT Controller rej...

Page 171: ...s of the amplfiers used to measure motor voltage are checked This alarm occurs when voltage signals 3V or 2V 1 Cycle keyswitch 2 Factory reset Clear Eeprom 3 Replace controller 0XA54 LOGIC FAIL 1 Over voltage under voltage condition has been detected 1 Check battery for load induced voltage drop Low voltage could be causing an under voltage condition Check battery cables 2 Factory reset Clear Eepr...

Page 172: ...R TEMPERATURE reading in the TESTER menu check the sensor ohmic value and the sensor wiring If the sensor is OK improve the cooling of the motor If the warning is present when the motor is cool then the problem is inside the controller Replace controller 0XA65 BATTERY LOW Battery is 10 when the parameter BATTERY CHECK is set to 0 Check that the controller SET BATTERY parameter value matches the ba...

Page 173: ...d always ON Check valve wiring for any short Replace valve If no short found Replace controller 0XA74 EV2 valve driver shorted always ON Check valve wiring for any short Replace valve If no short found Replace controller 0XA74 EV3 valve driver shorted always ON Check valve wiring for any short Replace valve If no short found Replace controller 0XA74 EV4 valve driver shorted always ON Check valve w...

Page 174: ...any movement 2 Joystick out of range Potentiometer not centered Check VACC calibration 0XA80 FORWARD BACWARD Receives both forward and reverse signals at the same time Re program VACC If condition is still present check wiring If OK replace controller 0XA80 EMERGENCY No 12 volt input to controllers 1 Check for 12 volt output at DC DC converter 2 Check fuse F2 3 Check for 12 volts at RM3 and LM3 0X...

Page 175: ...oller 0XA96 ANALOG INPUT Analog to digital failure Cause This alarm occurs when the A D conversion of the analog inputs gives frozen value on all of the converted signals for more than 400msec The goal of this diagnosis is to detect a failure of the A D converter or a problem in the code flow that omits the refreshing of the analog signal conversion Troubleshooting If the problem occurs permanentl...

Page 176: ...configure the USB to CAN device 1 From the drop down menu Configuration select Can Device The following window will open 2 In this example an IXXAT device set with a Baud Rate of 125 kbps this depends on the controller and with Standard Protocol this means Zapi Protocol is selected After clicking the OK button a configuration window opens Tick the USE IXXAT CONFIGURATION box as shown ...

Page 177: ... In this example there is only one device 4 Proceed with the connection to the network nodes by clicking Connection then Set Node In the following example there is a master node node 3 0 and a slave node node 4 0 Node 3 0 is the Master Combi AC0 and drives the Right Traction Motor and the Hydraulic Pump Motor Node 4 0 is the Slave ACE0 Inverter and drives the Left Traction Motor ...

Page 178: ...the connection by clicking the Start button in the main window The status LED in the lower part of the window indicates successful operation while the central part of the window contains information concerning the software version node number nominal battery voltage and current the hour counter and finally alarms if present ...

Page 179: ...Procedures Making Changes to the Parameters To make changes to the paramters it is necessary to do both of the following 1 From the drop down menu Configuration select Enter Password In the window that appears enter the password 1122 and click OK ...

Page 180: ...ir values using the applicable and icons To save the changes you must click on the Store icon 4 It is possible to save the parameters list In the top left corner of the window select File then Save Specify the folder and file name selecting csv format so it can be opened as an Excel file 5 To reset to the default parameters select Memory then Restore 6 Lastly you can load a parameters list into th...

Page 181: ...new connection to the node may be required 9 In the Tester menu is is possible to have some measurements in real time of the digital input and output stage Active Off of analog input voltage valve or the values of some variables used for the motor or hydraulic control 10 You can see up to four measured variables at the same time When you select the desired variable you will be able to see its valu...

Page 182: ...the Function menu you can open the alarm Logbook This lists all alarms present or which have occured during operation of the controller In the table all alarms are listed with the number of occurences the inverer temperature and the time at which the event occurs ...

Page 183: ...eters and enter them into the Adjustments menu 2 You will see three settings Throttle Neutral Throttle Max and Throttle Min It is necessary to program each setting individually 3 Throttle Neutral With the joystick in the neutral position click Aquire next to Throttle Neutral The following dialogue box appears ...

Page 184: ...ck Aquire next to Throttle Max The same dialogue box appears displaying the value of the neutral position 6 Now push the joystick to its maximum position fully forward You will see the voltage rise as the joystick is moved 7 With the joystick at the maximum position click Stop Teach The dialogue box closes and the maximum value is stored Note do not release the joystick until Stop Teach has been p...

Page 185: ...ion 9 Now push the joystick to its minimum position fully backwards You will see the voltage drop as the joystick is moved 10 With the joystick at the minimum position click Stop Teach The dialogue box closes and the minimum value is stored Note do not release the joystick until Stop Teach has been pressed and the dialogue box closes 11 The traction joystick is now programmed ...

Page 186: ...Adjustments menu 2 You will see three settings Set Steer 0 Pos Set Steer Right and Set Steer Left It is necessary to program each setting individually 3 Note that when installing the feedback device to the machine when the wheels are in the straight ahead position the reading from the device should be 1 2 the maximum value approximately 5 V ...

Page 187: ...to the right Click Aquire next to Set Steer Right The following dialogue box will be displayed 7 With the wheels at the fully right position the voltage should be higher than the Set Steer 0 Pos value Press Stop Teach to store the value and close the dialogue box 8 Set Steer Left Steer the wheels fully to the left Click Aquire next to Set Steer Left The following dialogue box will be displayed 9 W...

Page 188: ...ear 1 Open the control side cowling 2 Locate the grease line attached to the lower left side of the base control box 3 Pump grease into the line until new grease appears around the ring gear 4 Rotate the turret in increments of 10 to 13 cm 4 to 5 inches at a time and repeat step 3 until the entire bearing has been greased Grease the Steer Cylinder Bearing 1 Remove the front base cover to access th...

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